Manufacturing Method of Liquid Crystal Display Device

ABSTRACT

A liquid crystal display device includes a TFT substrate having a display area in which pixels are arranged, and a terminal portion, a counter substrate disposed opposite to the TFT substrate, a sealing material formed in a periphery to bond the TFT and counter substrates together, and with a liquid crystal layer interposed between an orientation film formed on the TFT substrate and an orientation film formed on the counter substrate. A first, second, or third color filter is formed corresponding to each of the pixels in the display area of the TFT substrate, and an orientation film stopper is formed by an overlapping portion of the first, second, or third color filter at least in an area between the display area and the terminal portion of the TFT substrate so that a profile of the orientation film is defined by the orientation film stopper.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.13/798,317, filed Mar. 13, 2013, which is a continuation of U.S.application Ser. No. 13/557,710, filed Jul. 25, 2012, now U.S. Pat. No.8,421,964, which is a continuation of U.S. application Ser. No.12/790,063, filed May 28, 2010, now U.S. Pat. No. 8,233,119, thecontents of which are incorporated herein by reference.

CLAIM OF PRIORITY

The present application claims priority from Japanese Patent ApplicationJP 2009-133752 filed on Jun. 3, 2009, the content of which is herebyincorporated by reference into this application.

FIELD OF THE INVENTION

The present invention relates to a display device, and moreparticularly, to a liquid crystal display device configured to havecolor filters on the side of a TFT substrate and allow an effectiveapplication of an orientation film.

BACKGROUND OF THE INVENTION

In a conventional liquid crystal display device, there is provided a TFTsubstrate in which pixel electrodes, thin film transistors (TFTs) andthe like are arranged in a matrix form and a counter substrate in whichcolor filters and the like are formed at locations corresponding to thepixel electrodes of the TFT substrate is disposed opposite to the TFTsubstrate. A liquid crystal is interposed between the TFT substrate andthe counter substrate. Then, an image is formed by controlling thetransmittance of light of the liquid crystal molecules for each pixel.

In such a conventional liquid crystal display device, it is necessary toexactly match the pixel electrodes formed in the TFT substrate to thecolor filters formed in the counter substrate. However, the positioningaccuracy of the TFT substrate and the counter substrate is about 3 to 5μm, which should be taken into account in the allowance of the pattern.As a result, the transmittance of a liquid display panel is reduced.

On the other hand, when the color filters are formed on the side of theTFT substrate, the TFT substrate and the counter substrate can beroughly positioned to each other. In other words, when the color filtersare formed on the side of the TFT substrate, the alignment accuracy ofthe color filters with respect to the wiring and the TFTs in the TFTsubstrate can be set in accordance with the mask alignment accuracy inphoto processing, and can be set to about 1 μm. JP-A No. 357828/2002describes a configuration in which color filters are formed on the sideof the TFT substrate as described above.

Liquid crystal display devices have been used in a wide range ofapplications. Under such circumstances there is a demand to produceliquid display panels of different sizes. In particular, a variety ofsizes are expected to be available in small liquid crystal displaypanels. The liquid crystal display panel uses an orientation film ofpolyimide or other suitable resin in order to orient liquid crystal. Theorientation film has been formed by flexographic printing in the past.

However, the flexographic printing requires different plates for eachtype of orientation films to be printed. The production of the plate isa factor of the increase in the production cost of the liquid crystaldisplay panel. In recent years, as a measure to solve this problem,there has been developed a process for applying the orientation film byinkjet printing. However, when the orientation film is formed by inkjetprinting, it is necessary to reduce the viscosity of the orientationfilm when it is applied.

In this case, it is difficult to keep the orientation film in apredetermined area due to the reduced viscosity of the orientation film.For example, the orientation film flows to a portion of a sealingmaterial for bonding the TFT substrate and the counter substratetogether. When the orientation film is formed extending to the portionof the sealing material, the reliability of the sealing portion isreduced.

In order to prevent this, JP-A No. 145461/2008 describes a configurationin which ITO (Indium Tin Oxide), which is used as a pixel electrode, isformed to surround the display area so that the orientation film isconfined to a predetermined range. In this way, the orientation film isprevented from extending to the sealing portion.

According to JP-A No. 145461/2008, the configuration for confining anorientation film to a predetermined range is as follows. In a frame areabetween the display area and the sealing portion, a concavo-convexpattern is formed in an insulating film and is coated with ITOconstituting a pixel electrode. The concavo-convex pattern formed in theperiphery of the display area prevents the orientation film with a lowviscosity applied by inkjet printing, from extending beyond theperiphery of the display area.

However, the thickness of the ITO formed in the periphery of the displayarea is equal to the thickness of the ITO of the pixel electrode, about70 to 100 nm. It is not sufficient as a stopper for the orientation filmwhose thickness is about 150 nm. Further, the concavo-convex pattern isformed from an insulator with a thickness of about 300 nm, which is notsufficient to block the low viscosity orientation film.

SUMMARY OF THE INVENTION

It is desirable to be able to apply the orientation film by inkjetprinting, without an increase in the production cost while maintainingthe reliability of the sealing portion.

The present invention overcomes the above problem by the followingmeans.

(1) There is provided a liquid crystal display device including a TFTsubstrate having a display area in which pixels each having a pixelelectrode and a TFT are arranged in a matrix form, and a countersubstrate disposed opposite to the TFT substrate. The TFT substrate andthe counter substrate are bonded together by a sealing material formedin the periphery. A liquid crystal layer is interposed between anorientation film formed in the TFT substrate and an orientation filmformed in the counter substrate. A first color filter, a second colorfilter, or a third color filter is formed corresponding to each of thepixels in the display area of the TFT substrate. An orientation filmstopper is formed by an overlapping portion of the first color filter,the second color filter, or the third color filter, between the displayarea of the TFT substrate and the sealing material. A profile of theorientation film formed in the TFT substrate is defined by theorientation film stopper.

(2) In the liquid crystal display device described in (1), theorientation film stopper is formed of two layers of color filters.

(3) In the liquid crystal display device described in (1), theorientation film stopper is formed of three layers of color filters.

(4) There is provided a liquid crystal display device including a TFTsubstrate having a display area in which pixels each having a pixelelectrode and a TFT are arranged in a matrix form, and a countersubstrate disposed opposite to the TFT substrate. The TFT substrate andthe counter substrate are bonded together by a sealing material formedin the periphery. A liquid crystal layer is interposed between anorientation film formed in the TFT substrate and an orientation filmformed in the counter substrate. A distance between the TFT substrateand the counter substrate is defined by a columnar spacer. A first colorfilter, a second color filter, or a third color filter is formedcorresponding to each of the pixels in the display area of the TFTsubstrate. A first orientation film stopper is formed by an overlappingportion of the first color filter, the second color filter, or the thirdcolor filter, between the display area of the TFT substrate and thesealing material. A profile of the orientation film formed in the TFTsubstrate is defined by the first orientation film stopper. A secondorientation film stopper is formed by the same process of the columnarspacer on the outside of the display area of the counter substrate. Aprofile of the orientation film formed in the counter substrate isdefined by the second orientation film stopper.

(5) There is provided a liquid crystal display device including a TFTsubstrate having a display area in which pixels each having a pixelelectrode and a TFT are arranged in a matrix form, and a countersubstrate disposed opposite to the TFT substrate. The TFT substrate andthe counter substrate are bonded together by a sealing material formedin the periphery. A liquid crystal layer is interposed between anorientation film formed in the TFT substrate and an orientation filmformed in the counter substrate. A first color filter, a second colorfilter, or a third color filter is formed corresponding to each of thepixels in the display area of the TFT substrate. A light shielding filmis formed by the overlapping of the first color filter, the second colorfilter, or the third color filter. An orientation film stopper is formedby an overlapping portion of the first color filter, the second colorfilter, or the third color filter, between the display area of the TFTsubstrate and the sealing material. A profile of the orientation filmformed in the TFT substrate is defined by the orientation film stopper.A height of the orientation film stopper is greater than a height of thelight shielding film formed in the display area of the TFT substrate.

(6) There is provided a liquid crystal display device including a TFTsubstrate having a display area in which pixels each having a pixelelectrode and a TFT are arranged in a matrix form, and a countersubstrate disposed opposite to the TFT substrate. The TFT substrate andthe counter substrate are bonded together by a sealing material formedin the periphery. A liquid crystal layer is interposed between anorientation film formed in the TFT substrate and an orientation filmformed in the counter substrate. A first color filter, a second colorfilter, or a third color filter is formed corresponding to each of thepixels in the display area of the TFT substrate. A light shielding filmis formed on the TFT, in addition to the first color filter, the secondcolor filter, or the third color filter. An orientation film stopper isformed by an overlapping portion of the first color filter, the secondcolor filter, or the third color filter, between the display area of theTFT substrate and the sealing material. A profile of the orientationfilm formed in the TFT substrate is defined by the orientation filmstopper.

(7) There is provided a liquid crystal display device including a TFTsubstrate having a display area in which pixels each having a pixelelectrode and a TFT are arranged in a matrix form, and a countersubstrate disposed opposite to the TFT substrate. The TFT substrate andthe counter substrate are bonded together by a sealing material formedin the periphery. A liquid crystal layer is interposed between anorientation film formed in the TFT substrate and an orientation filmformed in the counter substrate. A first color filter, a second colorfilter, or a third color filter is formed corresponding to each of thepixels in the display area of the TFT substrate. A light shielding filmis formed on the TFT, in addition to the first color filter, the secondcolor filter, or the third color filter. An orientation film stopper isformed by an overlapping portion of the light shielding film and thefirst color filter, the second color filter, or the third color filter,between the display area of the TFT substrate and the sealing material.A profile of the orientation film formed in the TFT substrate is definedby the orientation film stopper.

According to the present invention, it is possible to apply theorientation film by inkjet printing, without reducing the reliability ofthe sealing portion and without a need to have an additional productionprocess. As a result, the production cost of the liquid crystal displaydevice can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a liquid crystal display device to which thepresent invention is applied;

FIG. 2 is a cross-sectional view of a display area of the liquid crystaldisplay device according to a first embodiment;

FIG. 3 is a top view of the arrangement of color filters in a TFTsubstrate;

FIG. 4 is a top view of the TFT substrate according to the firstembodiment;

FIG. 5 is a top view of the periphery of the TFT substrate according tothe first embodiment;

FIG. 6 is a cross-sectional view taken along line A-A of FIG. 5;

FIG. 7 is a top view of a counter substrate according to the firstembodiment;

FIG. 8 is a top view of the periphery of the counter substrate accordingto the first embodiment;

FIG. 9 is a cross-sectional view taken along line B-B of FIG. 8;

FIG. 10 is a cross-sectional view of the periphery of the liquid crystaldisplay device according to the first embodiment;

FIG. 11 is a top view of the periphery of the TFT substrate according toa second embodiment;

FIG. 12 is a cross-sectional view taken along line C-C of FIG. 11;

FIG. 13 is a cross-sectional view of the periphery of the liquid crystaldisplay device according to the second embodiment;

FIG. 14 is a cross-sectional view of the periphery of the TFT substrateaccording to a third embodiment;

FIG. 15 is a cross-sectional view of the display area of the liquidcrystal display device according to a fourth embodiment; and

FIG. 16 is a cross-sectional view of the periphery of the TFT substrateaccording to the fourth embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention will be described indetail below.

First Embodiment

FIG. 1 is a top view of a liquid crystal display device used forelectronic devices such as mobile phones, which is an example of theliquid crystal display device in which the present invention is used. InFIG. 1, a counter substrate 200 is disposed above a TFT substrate 100. Aliquid crystal layer is interposed between the TFT substrate 100 and thecounter substrate 200. The TFT substrate 100 and the counter substrate200 are bonded together by a sealing material 15 formed in theperiphery.

In FIG. 1, the liquid crystal display device is sealed by droppingliquid crystal into the liquid crystal display device. Thus, no sealinghole of the liquid crystal is formed in the liquid crystal displaydevice. The TFT substrate 100 is made greater than the counter substrate200. A terminal portion 150 is formed in a portion of the TFT substrate100 extending beyond the counter substrate 200. The liquid crystaldisplay panel is supplied with power, image signals, scan signals, andthe like, from the terminal portion 150.

Further, an IC driver 50 is formed in the terminal portion 150 to drivescan lines, image signal lines, and the like. The IC driver 50 isdivided into three areas. In the center area of the three areas, animage signal driving circuit 52 is provided. A scan signal drivingcircuit 51 is provided in the two areas on both sides of the centerarea.

In the display area 10 of FIG. 1, scan lines, not shown, extend in thelateral direction and are arranged in the vertical direction. Further,image signal lines, not shown, extend in the vertical direction and arearranged in the lateral direction. The scan lines are connected byleaders 31 to the scan signal driving circuit 51 of the IC driver 50. InFIG. 1, the scan line leaders 31 is provided on both sides of thedisplay area, in order to provide the display area 10 in the centralportion of the liquid crystal display device. For this reason, the scansignal driving circuit 51 is provided on both sides of the IC driver 50.While the image signal lines are connected to the IC diver 50 by imagesignal leaders 41 extending together to the lower side of the display.The image signal line leaders 41 are connected to the image signaldriving circuit 52 provided in the center area of the IC driver 50.

The space from the boundary of the display area 10 to the end of thecounter substrate is called a frame area. The frame area is expected tobe reduced, in particular in the small liquid crystal display device. InFIG. 1, a distance p from the boundary of the display area 10 to thesealing material 15 is about 1 mm in the small liquid crystal displaydevice.

An orientation film stopper, which will be described below, is formedbetween the boundary of the display area 10 and the sealing material 15.The orientation film stopper is formed both in the TFT substrate 100 andin the counter substrate 200. In FIG. 1, only first and secondorientation film stoppers 61 and 62 are formed in the TFT substrate 100,which are shown by the dotted lines. In this embodiment, as shown inFIG. 1, the orientation film stopper has a two-stage structure of thefirst and second orientation film stoppers. However, a one-stagestructure or a three- or more-stage structure can also be used.

FIG. 2 is a cross-sectional view of the configuration of the displayarea 10 of FIG. 1. FIG. 2 shows a cross section of the liquid crystaldisplay device of the so-called TN (Twisted Nematic) type. It is to beunderstood that the present invention is not limited to this type. Thepresent invention can also be applied to liquid crystal display devicesof IPS (In Plane Switching) type, VA (Vertical Alignment) type, or othertypes.

In FIG. 2, a TFT is formed on the TFT substrate 100. A gate electrode101 of Al or other metal is formed on the TFT substrate 100. Then, agate insulating film 102 of, for example, SiN is formed to cover thegate electrode 101 on the TFT substrate 100. A semiconductor layer 103of, for example, a-Si is formed on the gate insulating film 102. Thethickness of a-Si is, for example, 150 nm. In this embodiment, thesemiconductor layer 103 uses a-Si. However, poly-Si can also be used forthe semiconductor layer 103. The thickness of the semiconductor layer103 of poly-Si is about 50 nm. The present invention can also be appliedto the semiconductor layer 103 of poly-Si, although the configuration ofTFT is different in the use of poly-Si.

A drain electrode 105 and a source electrode 104 of, for example, Al areformed on both sides of the semiconductor layer 103. An n+Si layer notshown for an ohmic contact is formed between the semiconductor layer103, and the drain electrode 105 and the source electrode 104. Thethickness of the n+Si layer is, for example, about 50 nm. The drainelectrode 105 is connected to an image signal line 40. The sourceelectrode 104 is connected to a pixel electrode 111. The TFT is formedby the process described above. Further, in FIG. 2, the image signalline, which is formed in the same layer of the drain electrode 105, isformed on the gate insulating film 102.

An inorganic passivation film 106 is formed to cover the TFT and theimage signal line. The inorganic passivation film 106 has a role toprotect the TFT from impurity. The inorganic passivation film 106 isformed, for example, from SiN with a thickness of about 400 nm.

Color filters are formed on the inorganic passivation film 106. Thecolor filters are formed by photo processing from a photosensitive resinin which a pigment is dispersed. The color filters of each pixel areprovided with different colors. In FIG. 2, a blue color filter 109 isformed in the pixel including the TFT on the right side. A green colorfilter 108 is formed in the pixel in the center. A red color filter 107is formed in the pixel on the left side. In FIG. 2, the TFT is shownonly in the pixel of the blue color filter 109, but actually is formedin all the pixels.

In FIG. 2, the color filters overlap to form a boundary portion of eachpixel. When the color filters are formed to overlap with each other, itis found to have characteristics of light shielding film. In thisembodiment, the color filters are formed to overlap with each other inthe boundary of each pixel in order to obtain the necessary lightshielding effect, without separately forming a black matrix on the TFTsubstrate 100. As a result, it is possible to omit the additionalprocess for forming the black matrix.

FIG. 3 is a top view of only the image signal lines, the scan lines, andthe red, green, blue color filters in the display area 10. In FIG. 3,the scan lines extend in the lateral direction and are arranged in thevertical direction. Further, the image signal lines extend in thevertical direction and are arranged in the lateral direction. The areassurrounded by the scan lines and the image lines are pixels.

The color filters are formed in a strip shape to cover the image signallines on both sides of each pixel. Thus, two color filters are formed tooverlap with each other on the image signal line. A light shielding film80 is formed in the overlapping portion of the two color filters.Although not shown in FIG. 3, the light shielding film 80 with the sameconfiguration is also formed on the TFT. The color filters are formed byphoto processing to leave each color filter in the desired location. Inthis way, it is possible to form the overlapping portion of the colorfilters, or the light shielding film 80, in any location.

Returning to FIG. 2, the pixel electrode 111 is formed on the colorfilter in the pixel area. The pixel electrode 111 is connected to thesource electrode 104 by a through hole formed in the color filter andthe inorganic passivation film 106. The pixel electrode 111 is formedfrom ITO with a thickness of, for example, 70 μm. An orientation film112 for orienting the liquid crystal is formed to cover the pixelelectrode 111. In this embodiment, the orientation film 112 is appliedby inkjet printing, and then is burned and solidified.

In FIG. 2, the counter substrate 200 is disposed opposite to the TFTsubstrate 100. In the counter substrate 200, a counter electrode 201 isformed from ITO. A columnar spacer 202 is formed on the countersubstrate 200 to define the distance between the TFT substrate 100 andthe counter substrate 200. The columnar spacer 202 comes into contactwith the color filters constituting the light shielding film 80 todefine the distance between the TFT substrate 100 and the countersubstrate 200.

The orientation film 112 is formed to cover the counter electrode 201and the columnar spacer 202. In this embodiment, the orientation film112 on the side of the counter electrode 201 is also applied by inkjetprinting, and then is burned and solidified. A liquid crystal layer 300is interposed between the TFT substrate 100 and the counter substrate200. The liquid crystal layer 300 is sealed by the sealing material 15as shown in FIG. 1.

FIG. 4 is a top view of the side of the TFT substrate 100. In FIG. 4,the sealing material 15 is formed in the portion of the TFT substrate100 to which the counter substrate 200 is bonded. The orientation filmstopper is formed between the outer periphery of the display area 10 andthe sealing material 15. The orientation film stopper has a two-stagestructure of the first orientation film stopper 61 and the secondorientation film stopper 62.

In order to apply the orientation film 112 by inkjet printing, it isnecessary to reduce the viscosity of the orientation film 112. When theviscosity of the orientation film 112 is reduced, the orientation film112 flows. This makes it difficult to define the area of the orientationfilm 112, in particular, on the outside of the display area 10. When theorientation film 112 flows to the portion in which the sealing material15 is formed, the adhesive force of the sealing material 15 is reduced.This leads to a problem with the reliability of the sealing portion.

In the present invention, as shown in FIG. 4, the orientation filmstopper is formed to define the area to which the orientation film 112should be applied. The orientation film stopper has the two-stagestructure. In this way, when the orientation film 112 flows beyond thefirst orientation film stopper 61, the second orientation film stopper62 can prevent the orientation film 112 from flowing to the outside ofthe display area 10. Here, when one stage of orientation film stoppercan prevent the flow of the orientation film 112, a one-stage structurecan be used. It is also possible to use a three- or more-stage structurewhen two stages of orientation film stopper are not sufficient toprevent the outflow of the orientation film 112.

FIG. 5 is a detailed top view of the periphery of FIG. 4. FIG. 6 is across-sectional view taken along line A-A of FIG. 5. In FIG. 5, thesealing material 15 is formed in the end portion of the TFT substrate100. The first and second orientation film stoppers 61 and 62 are formedby color filters between the end portion of the display area 10 and thesealing material 15. The orientation film 112 is defined by the firstorientation film stopper 61.

FIG. 6 is a cross-sectional view taken along line A-A of FIG. 5, showingthe configuration of the orientation film stopper. In FIG. 6, the gateinsulating film 102 and the inorganic passivation film 106 are formed onthe TFT substrate 100, on which the color filters are formed. In FIG. 6,the pixel in the outermost periphery is the red pixel, so that the redcolor filter 107 extends to the periphery.

The green color filter 108 is formed to partially overlap the end of theread color filter 107. The red color filter 107 and the green colorfilter 108 overlap with each other to form the first orientation filmstopper 61. The blue color filter 109 is formed to partially overlap theend of the green color filter 108. The green color filter 108 and theblue color filter 109 overlap with each other to form the secondorientation film stopper 62.

In FIG. 6, the outer periphery of the orientation film 112 applied byinkjet printing is defined by the first orientation film stopper 61.Thus, when the viscosity of the orientation film 112 is small, theorientation film 112 does not flow to the outside of the firstorientation film stopper 61. However, if any defect is present in thefirst orientation film stopper 61, the orientation film 112 may flow tothe outside of the first orientation film stopper 61. In this case, theoutflow of the orientation film 112 can be prevented by the secondorientation film stopper 62.

In FIG. 6, a width w1 of the first and second orientation film stoppers61 and 62 is about 10 μm. Also, a distance dl between the first andsecond orientation film stoppers 61 and 62 is about 10 μm. However, w1and d1 can be set to an arbitrary value.

In FIG. 6, a thickness h2 of the upper color filter and a thickness h1of the lower color filter are substantially equal to each other, about 2μm. However, the thickness h2 of the upper color filter is oftenslightly smaller than the thickness h1 of the lower color filter. Thisis due to the leveling effect in the application of the color filter.The upper color filter with a thickness of about 1 μm is sufficient toprevent the outflow of the orientation film 112.

In the display area 10 shown in FIG. 2, the light shielding film 80 isformed by the overlapping portion of the two color filters, in which thethickness of the upper color filter may be made much smaller than thethickness of the lower color filter. This is because the presence of alarge step between the color filters may have effect on the orientationof the liquid crystal. In such a case, the upper color filter, which isformed as the orientation film stopper in the periphery, should have agreater thickness than the thickness of the upper color filter formed asthe light shielding film 80 of the display area 10.

Such a configuration can be provided, for example, by increasing theamount of overlap between the lower and upper color filters in theperiphery. In other words, the greater the amount of overlap between thelower and upper color filters, the smaller the reduction in the filmthickness of the upper color filter due to the leveling effect.

Another method of reducing the thickness of the upper color filter morewithin the display area 10 than in the periphery of the display area 10is to pattern the upper color filter by half exposure in the overlappingportion in the display area 10. The cross-linking reaction in the halfexposed portion does not progress further than in the fully exposedportion. Thus, the color filter is formed thin in the half exposedportion after it is developed.

As described above, it is possible to arbitrarily set the shape of thelight shielding film 80 formed by the overlapping of the color filtersin the display area 10, as well as the shape of the orientation filmstopper formed by the overlapping of the color filters in the outside ofthe display area 10. Further, the light shielding film 80 in the displayarea 10 and the orientation film stopper in the outside of the displayarea 10 can be formed at the same time. Thus, the number of processesremains unchanged.

The above description focuses on the configuration in which theorientation film 112 is formed by inkjet printing on the side of the TFTsubstrate 100. The orientation film 112 should be formed also on theside of the counter substrate 200. In the case of forming theorientation film 112 on the side of the counter substrate 200, the useof inkjet printing is advantageous in terms of the production cost.

FIG. 7 is a top view of the side of the counter substrate 200. In FIG.7, the sealing material 15 is formed in a portion of the countersubstrate 200 to which the TFT substrate 100 is bonded. The orientationfilm stopper is formed between the outer periphery of the display area10 and the sealing material 15. The orientation film stopper has atwo-stage structure of a third orientation film stopper 71 and a fourthorientation film stopper 72.

In order to apply the orientation film 112 by inkjet printing, it isnecessary to reduce the viscosity of the orientation film 112 when it isapplied. However, the orientation film 112 having a low viscosity flows,making it difficult to define the area of the orientation film 112, inparticular, on the outside of the display area 10. This is the same asthe case of the TFT substrate 100. When the orientation film 112 flowsto the portion in which the sealing material 15 is formed, the adhesiveforce of the sealing material 15 is reduced. This leads to a problemwith the reliability of the sealing portion.

In this embodiment, as shown in FIG. 7, the orientation film stopper isformed to define the area to which the orientation film 112 should beapplied. In the counter substrate 200, the orientation film stopper isformed from the same material of the columnar spacer 202 at the sametime. Thus, also in the counter substrate 200, there is no additionalprocess in the formation of the orientation film stopper. Theorientation film stopper has the two-stage structure. In this way, whenthe orientation film 112 flows beyond the third orientation film stopper71, the fourth orientation film stopper 72 can prevent the flow of theorientation film 112 to the outside. This is the same as the case of theTFT substrate 100. Of course, when one stage of orientation film stoppercan prevent the flow of the orientation film 112, a one-stage structurecan be used. It is also possible to use a three- or more-stage structurewhen two stages of orientation film stopper are not sufficient toprevent the outflow of the orientation film 112.

FIG. 8 is a detailed top view of the periphery of FIG. 7. FIG. 9 is across-sectional view taken along line B-B of FIG. 8. In FIG. 8, thesealing material 15 is formed in the end portion of the countersubstrate 200. The third orientation film stopper 71 and the fourthorientation film stopper 72 are formed from the same material andprocess of the columnar spacer 202, between the end of the display area10 and the sealing material 15. The orientation film 112 is defined bythe end of the third orientation film stopper 71.

FIG. 9 is a cross-sectional view taken along line B-B of FIG. 8, showingthe state of the orientation film stopper in the counter substrate 200.In FIG. 9, the third orientation film stopper 71 and the fourthorientation film stopper 72 are formed on the counter substrate 200, bythe same process of the columnar spacer 202. The width of theorientation film stopper is, for example, 10 μm.

A distance d2 between the orientation film stoppers 72 and 71 is, forexample, 10 μm. The orientation film stoppers of the counter substrate200 are formed in the same manner as the columnar spacer 202, having aheight h3 of, for example, about 3 to 5 μm.

In FIG. 9, the profile of the orientation film 112 is defined by thethird orientation film stopper 71. In this way, in the counter substrate200, the use of the third orientation film stopper 71 defines theprofile of the orientation film 112, ensuring that the orientation film112 remains without flowing to the sealing portion. As a result, thereliability of the sealing portion is not reduced. Further, theorientation film stopper of the counter substrate 200 is formed by thesame process of the columnar spacer 202, in which there is no increasein the production cost.

FIG. 10 is a cross-sectional view of the periphery of the liquid crystaldisplay panel, in which the TFT substrate 100 and the counter substrate200 are formed as described above and bonded together. In FIG. 10, theTFT substrate 100 and the counter substrate 200 are bonded together bythe sealing material 15 formed in the periphery. The liquid crystallayer 300 is interposed between the TFT substrate 100 and the countersubstrate 200.

In the TFT substrate 100, the red color filter 107 extends from thedisplay area 10. The green color filter 108 is formed to overlap the endof the red color filter 107, forming the first orientation film stopper61. Further, the blue color filter 109 is formed to overlap the end ofthe green color filter 108, forming the second orientation film stopper62. The profile of the orientation film 112 of the TFT substrate 100 isdefined by the first orientation film stopper 61.

In the counter substrate 200 of FIG. 10, the third orientation filmstopper 71 and the fourth orientation film stopper 72 are formed by thesame process of the columnar spacer 202. The profile of the orientationfilm 112 of the counter substrate 200 is defined by the thirdorientation film stopper 71. The first and second orientation filmstoppers 61 and 62 formed in the TFT substrate 100, and the third andfourth orientation film stoppers 71 and 72 formed in the countersubstrate 200, are arranged at positions shifted from each other. Inthis way, the color filters in the display area 10 as well as thecolumnar spacer 202 are allowed to define the distance between the TFTsubstrate 100 and the counter substrate 200 in the liquid crystaldisplay panel. As illustrated in FIG. 10, the orientation film stopper61 or 62 formed by overlapping the portion of the first color filter 107and the second color filter 108 or by overlapping the portion of thesecond color filter 108 and the third color filter 109 has a height lessthan a height of a gap between the TFT substrate 100 and the countersubstrate 200 so that the orientation film stopper 61 or 62 formed byoverlapping portions of the color filters formed on the TFT substratedoes not form a spacer having a height of the gap and a top surfacewhich contacts with the counter substrate 200.

In FIG. 10, the third and fourth orientation film stoppers 71 and 72 inthe counter substrate 200 are formed on the outside of the first andsecond orientation film stoppers 61 and 62 in the TFT substrate 100.However, the reverse arrangement is also possible. In other words, thefirst and second orientation film stoppers 61 and 62 of the TFTsubstrate 100 can be formed on the outside of the third and fourthorientation film stoppers 71 and 72 of the counter substrate 200.

Second Embodiment

In the first embodiment, the overlapping portion of the red color filter107 and the green color filter 108 forms the first orientation filmstopper 61 on the side of the TFT substrate 100. Similarly, theoverlapping portion of the green color filter 108 and the blue colorfilter 109 forms the second orientation film stopper 62 on the side ofthe TFT substrate 100. However, the method of forming the orientationfilm stopper is not limited to the above example, and other variousconfigurations can also be used.

FIG. 11 is a top view of another method of forming the orientation filmstopper on the side of the TFT substrate 100. FIG. 12 is across-sectional view taken along line C-C of FIG. 11. In FIG. 11, thesealing material 15 is formed in the end portion of the TFT substrate100. The first orientation film stopper 61 and the second orientationfilm stopper 62 are formed by the color filters between the end of thedisplay area 10 and the sealing material 15. The orientation film 112 isdefined by the first orientation film stopper 61. FIG. 11 is differentfrom FIG. 5 of the first embodiment in the method of forming theorientation film stopper.

FIG. 12 is a cross-sectional view taken along line C-C of FIG. 11,showing the configuration of the orientation film stopper. FIG. 12 isthe same as FIG. 6 except for the method of forming the orientation filmstopper, so that the description of the same configuration will beomitted. In FIG. 12, the red color filter 107 extends to under the bluecolor filter 109 constituting the second orientation film stopper 62.

The first orientation film stopper 61 is formed by placing the greencolor filter 108 on the red color filter 107. Further, the secondorientation film stopper 62 is formed by placing the blue color filter109 on the red color filter 107. In this embodiment, the orientationfilm stopper can be formed without forming a step between the colorfilters. In FIG. 13, the thickness h1 of the lower color filter and thethickness h2 of the upper color filter are substantially equal to eachother. Also in this embodiment, the thickness h2 of the upper colorfilter can be adjusted by the leveling effect.

FIG. 13 is a cross-sectional view of the periphery of the liquid crystaldisplay panel using the TFT substrate 100 according to this embodiment.FIG. 13 is the same as FIG. 10 except for the method of forming thefirst and second orientation film stoppers 61 and 62 formed in the TFTsubstrate 100. The effect of the second embodiment is the same as theeffect of the first embodiment.

Third Embodiment

A third embodiment addresses the case in which the height of theorientation film stopper is not sufficient in the formation of theorientation film stopper by the overlapping of the color filters on theTFT substrate 100. FIG. 14 is a cross-sectional view of the periphery ofthe TFT substrate 100 in this embodiment. The cross-sectional viewcorresponds to FIG. 12 in the second embodiment.

In FIG. 14, the red color filter 107 extends to the second orientationfilm stopper 62. The first orientation film stopper 61 is formed byplacing the green color filter 108 on the red color filter 107. Then,the blue color filter 109 is further placed on the green color filter108. The first orientation film stopper 61 is formed by the overlappingof the three color filters. Thus, the height of the orientation filmstopper can be made large, even to 4 μm or more. This configurationensures to prevent the orientation film 112 from flowing to the outsideof the display area 10.

The second orientation film stopper 62 has the very same configurationas that of the first orientation film stopper 61, and can be formed bythe same process of the first orientation film stopper 61. The thirdembodiment is the same as the second embodiment in the cross section ofthe periphery of the liquid crystal display panel formed in such a waythat the TFT substrate 100 and the counter substrate 200 are bondedtogether, except that the first and second orientation film stoppers 61and 62 have the three-layer structure. Thus, the repeated descriptionwill be omitted here.

Fourth Embodiment

In the above embodiments, the overlapping of the color filters is usedas the light shielding film 80 in the display area 10. However, thelight shielding film 80 formed by the overlapping of the color filtersmay not be sufficient to shield, in particular, the TFT from the light.FIG. 15 is a cross-sectional view of the configuration that solves thisproblem.

In FIG. 15, a black matrix 110 is formed on the TFT substrate 100, inaddition to the color filters. The black matrix 110 is formed from aphotosensitive resin with titanium black, carbon black, and the like,dispersed therein, having an excellent light shielding property. Alsothe black matrix 110 is formed by photo processing. In this embodiment,the number of processes is increased by the use of the photo processing.However, the OFF current of the TFT can be reduced, so that the imagequality can be increased.

Even in the configuration shown in FIG. 15, the present invention canalso be applied in the same manner as described in the first to thirdembodiments. Further, instead of using the color filter, the blackmatrix 110 can be placed on the upper layer as an orientation filmstopper in the periphery. In this case, the black matrix 110 canfunction as a stopper of the orientation film 112, and can function asmeans for preventing the reduction in the contrast due to the externallight reflection in the periphery. FIG. 16 is a cross-sectional view ofthe TFT substrate 100 in this state.

In FIG. 16, the red color filter 107 extends to the periphery. The blackmatrix 110 is formed on the red color filter 107. In this embodiment,the black matrix 110 has only one stage. In other words, the orientationfilm stopper includes only the first orientation film stopper 61. InFIG. 16, the black matrix 110 is formed wider than the upper fluorescentlayer of the first to third embodiments. The wide width of the blackmatrix 110 prevents the reflection of external light in the periphery.As a result, the contrast can be increased in the periphery of thedisplay.

The above embodiments have been described assuming that the red, green,and blue color filters are formed in this order. However, the order ofthe formation of the color filters is not limited to this example, andcan be set arbitrarily.

What is claimed is:
 1. A liquid crystal display device comprising: a TFTsubstrate including a display area in which pixels each having a pixelelectrode and a TFT are arranged in a matrix form, and a terminalportion; a counter substrate disposed opposite to the TFT substrate; asealing material formed in a periphery of at least one of the TFTsubstrate and the counter substrate to bond the TFT substrate and thecounter substrate together; and a liquid crystal layer interposedbetween an orientation film formed on the TFT substrate and anorientation film formed on the counter substrate; wherein a first colorfilter, a second color filter, or a third color filter is formedcorresponding to each of the pixels in the display area of the TFTsubstrate; wherein an orientation film stopper is formed by anoverlapping portion of the first color filter, the second color filter,or the third color filter, at least in an area between the display areaand the terminal portion of the TFT substrate; and wherein a profile ofthe orientation film between the display area and the terminal portionof the TFT substrate is defined by the orientation film stopper.
 2. Theliquid crystal display device according to claim 1, wherein theorientation film stopper is formed of two layers of color filters. 3.The liquid crystal display device according to claim 1, wherein theorientation film stopper is formed of three layers of color filters. 4.A liquid crystal display device comprising: a TFT substrate including adisplay area in which pixels each having a pixel electrode and a TFT arearranged in a matrix form, and a terminal portion; a counter substratedisposed opposite to the TFT substrate; a sealing material formed in aperiphery of one of the TFT substrate and the counter substrate to bondthe TFT substrate and the counter substrate together; and a liquidcrystal layer interposed between an orientation film formed on the TFTsubstrate and an orientation film formed on the counter substrate;wherein a columnar spacer is provided on the counter substrate fordefining a distance between the TFT substrate and the counter substrate;wherein a first color filter, a second color filter, or a third colorfilter is formed corresponding to each of the pixels in the display areaof the TFT substrate; wherein a first orientation film stopper is formedby an overlapping portion of the first color filter, the second colorfilter, or the third color filter, at least in an area, between thedisplay area and the terminal portion of the TFT substrate; wherein aprofile of the orientation film between the display area and theterminal portion of the TFT substrate is defined by the firstorientation film stopper; wherein a second orientation film stoppercorresponding to the columnar spacer is formed outside of the displayarea of the counter substrate; and wherein a profile of the orientationfilm formed in the counter substrate is defined by the secondorientation film stopper.
 5. A liquid crystal display device comprising:a TFT substrate including a display area in which pixels each having apixel electrode and a TFT are arranged in a matrix form, and a terminalportion; a sealing material formed in a periphery of at least one of theTFT to substrate and the counter substrate to bond the TFT substrate andthe counter substrate together; and a liquid crystal layer interposedbetween an orientation film formed on the TFT substrate and anorientation film formed on the counter substrate, wherein a first colorfilter, a second color filter, or a third color filter is is formedcorresponding to each of the pixels in the display area of the TFTsubstrate; wherein a light shielding film is provided on the TFTsubstrate, in addition to the first color filter, the second colorfilter, or the third color filter; and wherein an orientation filmstopper is formed by an overlapping portion of the light shielding filmand the first color filter, the second color filter, or the third colorfilter, at least in an area between the display area and the terminalportion of the of the TFT substrate; and wherein a profile of theorientation film between the display area and the terminal portion ofthe TFT substrate is defined by the orientation film stopper.